4qd Pro-120 Series Instruction Manual - Page 7

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at the controller to fall so low that the controller

detects a fault condition and the relay will switch off.

On the 24v versions, use of wire that is too long

(and/or too thin) will cause loss of power but will not

harm the controller although the decoupling

capacitor (see 'features' diagram above) may heat

up. Heat will shorten the operating life of capacitors.

Crimp Contacts

You must use fully insulated crimps: the power

connections are close to each other and uninsulated

crimps may short out and cause damage. Best of all

use 'F type' crimps with vinyl covers. 4QD can

supply these pre-crimped only as they require a

special crimp tool.

8.02

Motor wiring

This is not quite so critical as battery wiring: too

long and/or too thin wire will cause a loss of

performance, it will get and will waste battery power

but will not damage the controller. However, wire

which is too thick will do no harm either so we

recommend the same wire for the motor as for the

battery.

9 Controls

The mating connector supplied is

suitable only for the correct size of wire.

Acceptable wire sizes are:

7 stranded 0.22-0.25mm²

24 AWG (7/32 AWG)

It is an Insulation Displacement

Connector (IDC):

Do not strip the insulation from the

wires, simply push them into the top part

of the open connector, from the front

(visible in the diagram) and squeeze it

closed in a vice or with suitable parallel

action pliers. As you do so, the tines of the contacts

bite through the insulation to make contact with the

conductors.

You can re-open a closed connector by gently

moving the tabs at the sides of the top cover outward

to disengage the latches while lifting the cover

slightly, one side at a time.

Pro-120 controller instructions

8.03

Circuit breaker

A fuse or circuit breaker may be fitted if required.

The main advantage is that it will enable the battery

or motor to be disconnected in the event of an

emergency or for security. A circuit breaker will not

protect the drive in the event of a fault: MOSFETs

fail far faster than a circuit breaker can operate.

This may be fitted in the battery lead as shown: take

care not to increase the wiring length too much.

Also, certain types of breaker can have the same

effect as increased battery lead length. A breaker in

the motor may therefore be best: it will enable you to

quickly disconnect the motor in an emergency. Also

with the motor disconnected, freewheeling becomes

possible. It is also possible to get a battery isolator

switch - these are normally fitted to lorries, buses

and boats to isolate the battery in an emergency - but

this is not required as the Pro-120 has a power relay

which effectively disconnects the battery (except for

a small bleed resistor).

8.04

Battery condition meter.

This should connect between Pins B and F (white

and green on the diagram). White is connected via

the ignition switch to battery positive and green is

always connected via the wiring to the battery

negative.

Open

Closed

A B C D E F

A yellow: +24v (V Batt) to Ignition

B white:

Ignition

C black:

Reverse (0v = forward, >5v = reverse)

D red:

Max speed (about 7v when ign on)

E blue:

Wiper (0 to Max Speed, as pot is varied)

F green:

0v (Min speed)

Wire which is too thin will not make good contact.

Wire which is too thick will damage the tines which

may short to each other

Solid wire will quickly break with use.

Under no circumstances should you solder to the

connector or the circuit board.

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